Purified Water Plant – Operation and Regeneration

Standard Operating Procedure (SOP) to define the procedure for operation and regeneration of the Purified Water Plant (Mixed bed unit).

SOP for Purified Water Plant

1.0   PURPOSE:

    • To define the procedure for operation and regeneration of Purified Water Plant (Mixed bed unit).

2.0   SCOPE:

    • This procedure is applicable to the operation and regeneration of the Purified water Plant (Mixed bed Unit).

3.0   REFERENCES:

    • Water System User Manual
    • IP/BP

4.0   RESPONSIBILITY – SOP FOR WATER PLANT:

    • Technician of the Water Plant shall be responsible – 

    • To operate and regenerate the water plant as per the standard procedure.
    • Periodically maintaining the entire log sheet, UV lamp replacement status label and record.
    • To maintain the water plant in good working condition.
    • The maintenance supervisor shall be responsible –

    • To check the entire log sheet, UV lamp replacement status label and record.
    • Ensure the water plant operation and regeneration process is as per SOP and checks the records.
    • To check the parameter and get the water samples approved by the quality control department daily.
    • To maintain the water plant performance and quality of water as per specification.
    • Quality control shall be responsible-

    • To check water quality and parameters and ensure the maintenance of records.
    • To check the water plant performance and optimize it.
    • The Head of the Department shall be responsible-

    • To check the water plant operation and regeneration process.
    • To check water quality and parameters and ensure the maintenance of records.
    • Check the water plant performance and optimize it.

5.0   ABBREVIATIONS – SOP FOR WATER PLANT:

    • Dept: DepartmentPurified Water Plant
    • LPH: Litre per hour
    • NMT: Not More Than
    • RO: Reverse Osmosis
    • UV: Ultra Violet

6.0   PROCEDURE – SOP FOR WATER PLANT:

  • Interchange of Mixed Bed for Operation:

    • After every 24 hours (preferable at the start of the shift) mixed bed to be interchanged. Or as and when required due to an increase in conductivity of purified water (conductivity limit NMT 5.1 µS/ cm).
    • Normal start-up and operation of Mixed bed 1:
    • Stop the RO water transfer pump and put the OFF UV sanitizer unit by keeping the system on manual mode.
    • Close valve V07, V16A & V17A.
    • Open valve V01, V02 & V09.
    • Start the RO water transfer pump manually and drain the water at least for 5 min.
    • Check the pH and conductivity of water (conductivity limit is NMT 5.1 µS/ cm (micro siemens) and pH within 5 – 7).
    • Ensure that the 3KL RO water tank has more than 50% of the water level.
    • Put on the UV sanitization unit and open the valve V07 to permit the purified water to 5 KL Purified water storage tank.
    • Close the valve V09 to stop drainage and switch the system in AUTO mode.
    • Normal start-up and operation of Mixed bed 2:

    • Stop the RO water transfer pump and put the OFF UV sanitizer unit by keeping the system on manual mode.
    • Close valve V01, V07 & V07A.
    • Open valve V16A, V01A, V02A & V09A.
    • Start the RO water transfer pump manually and drain the water at least for 5 min.
    • Check the pH and conductivity of water (conductivity limit is NMT 5.1 µS/ cm and pH within 5 – 7).
    • Ensure that the 3KL RO water tank has more than 50% of the water level.
    • Put on the UV sanitization unit “ON” and open the valve V07A & V17A to permit the purified water to 5 KL Purified water storage tank.
    • Close the valve V09A to stop drainage and switch the system in AUTO mode.
  • Regeneration of Mixed bed 1 (Water Plant):

    • Stop the RO water transfer pump and close the valve V16A & V17A. Details of regeneration to be recorded in Annexure-2.
    • Backwash :
    • Open the valves V01, V06, V03 & V12 and ensure that all other valves are properly closed.
    • Start the RO water transfer pump and then maintain the flow pressure between 1.0 to 1.2 kg/ cm² by adjusting the discharge valve of the pump.
    • Backwash the unit up to 25 min.
    • Stop the permeate water transfer pump and then leave the unit at least for 20 min. for bed settling.
  • Alkali regeneration of Water Plant:

    • Take 10 kg of Caustic Flakes (Sodium Hydroxide) in a Caustic Dilution Tank and add 100 liters of purified water.
    • Open valve V10, V02 & V05 fully and ensure that all other valves should be closed and Rinse the system for 5 minutes.
    • Along with the above operation, open the valve V11and adjust the flow so as to inject the caustic solution in 25-30 minutes.
    • After complete caustic injection, close the valve V11 and flush the system for 45 minutes for slow rinse.
    • Along with the above operation closed valve V10 & open the valve V01 for 25-30 (until pH comes to 7-8) minutes for fast rinse.
  • Acid regeneration of Water System:

    • Take 25 liters of HCl 33% (Hydrochloric acid) in the Acid Measuring tank and add 100 liters of purified water.
    • Open valves V10, V04 & V09 and ensure that all remaining valves are closed. Rinse the system for 5 minutes.
    • Along with the above operation open valve V11 and adjust the flow of water so as to inject the acid within 25-30 minutes.
    • After complete injection closes the valve V11 and then flush the system for 45- 50 minutes for slow rinse.
    • Along with the above operation closed the valve V10 & keep open the valve V01 for 25-30minutes (until pH comes to 6-7) for fast rinse.
    • Air Mixing in Water Plant:

    • Open-air inlet valve V13, V08, and air release valve V12 and ensure that all other valves are properly closed.
    • Adjust 1.0 to 1.5 kg air pressure on the gauge. Keep air ‘ON’ for 25 minutes. Observe the mixing of resins.
    • Close air valve V13, V08, and valve V12.
    • Open the valvesV01, V02, V09 and then operate the RO water transfer pump manually and ensure that the pneumatically operated flow diversion valve (XFDV 02) is closed & drain the water until the pH comes between 6.5-7.0.
    • The water sample shall be sent to QC to check the conductivity & pH of the water.
    • If the water sample is approved from QC then open the valve (XFDV 02) to allow the water to the Purified water storage tank and switch the system in AUTO mode.
    • If the conductivity observed high, then put the system on circulation (Mixed bed unit & RO storage tank), until the conductivity comes down to the specified limit.
    • Regeneration of Mixed bed 2 in Water Plant:

    • Stop the RO water transfer pump and close the valve V01, V07 & V17A, and open valve V16A. Details of regeneration to be recorded in Annexure-2.
    • Backwash :
      • Open the valves V01A, V06A, V03A & V12A and ensure that all other valves are properly closed.
      • Start the RO water transfer pump and then maintain the flow pressure between 1.0 to 1.2 Kg/ cm² by adjusting the discharge valve of the pump.
      • Backwash the unit up to 25 min.
      • Stop the permeate water transfer pump and then leave the unit at least for 20 min. for bed settling.
    • Alkali regeneration of Water Plant:

      • Take 10 kg of Caustic Flakes (Sodium Hydroxide) in a Caustic Dilution Tank and add 100 liters of purified water.
      • Open valve V10A, V02A & V05A fully and ensure that all other valves should be closed and Rinse the system for 5 minutes.
      • Along with the above operation open valve V11A and adjust the flow so as to inject the caustic solution in 25-30 minutes.
      • After complete caustic injection, close the valve V11A and flush the system for 45 minutes for slow rinse.
      • Along with the above operation closed valve V10A & open the valve V01A for 25-30 minutes (until pH comes to 7-8) for fast rinse.
    • Acid regeneration:

      • Take 25 liters of HCl 33% (Hydrochloric acid) in the Acid Measuring tank and add 100 liters of purified water.
      • Open valves V10A, V04A & V09A and ensure that all remaining valves are closed. Rinse the system for 5 minutes.
      • Along with the above operation open valve V11A and adjust the flow of water so as to inject the acid within 25-30 minutes.
      • After complete injection close the valve V11A and then flush the system for 45- 50 minutes for slow rinse.
      • Along with the above operation closed the valve V10A & open the valve V01A for 25-30 minutes (until pH comes to 6-7) for fast rinse.
    • Air Mixing:

      • Open-air inlet valve V13A, V08A, and air release valve V12A and ensure that all other valves are properly closed.
      • Adjust 1.0 to 1.5 kg air pressure on the gauge. Keep air ‘ON’ for 25 minutes. Observe the mixing of resins.
      • Close air valve V13A, V08A, and valve V12A.
      • Open the valvesV01A, V02A, V09A, and then operate the RO water transfer pump manually and ensure that the pneumatically operated flow diversion valve (XFDV 02) is closed & drain the water until the pH comes between 6.5-7.0.
      • The water sample shall be sent to QC to check the conductivity & pH of the water.
      • If the water sample is approved from QC then open the valve (XFDV 02) to allow the water to the Purified water storage tank and switch the system in AUTO mode.
      • If the conductivity observed high, then put the system on circulation (Mixed bed unit & RO storage tank), until the conductivity comes down to the specified limit.
    • Frequency of Water Quality monitoring: 

      • Physical parameters (pH and conductivity) of water to be monitored by the engineering department at least every 4 hours and as and when required (after regeneration and interchange of mixed bed) observation to be recorded in Annexure- 1.
    • The frequency for the regeneration of Water Plant:

      • If the conductivity of return loop water exceeds 5.1 µs (micro siemens)/ cm, the mixed bed to be regenerated.
      • If the Mixed bed unit remains idle for more than 8 hours, then the Mixed bed unit shall be flushed with water for at least 5 min.
    • UV Sanitizers:
      • The lifetime of UV lamp (after mixed bed) is 12000 working hours or the intensity of UV lamp NLT 95%, which one is earlier.
      • The lifetime of the UV lamp (after PW storage tank) is 365 days or the intensity of UV lamp NLT 95%, which one is earlier.
    • Water Sampling Procedure:
      • Purified water shall be sampled by QC person on daily basis from Sampling point no. PW01, PW49 & PW51.
      • QC analysis report shall be recorded in Annexure. 1
      • After regeneration of the Mixed bed water sample shall be collected from the mixed bed outlet for checking of pH & conductivity of water.
      • The result to be recorded in Annexure-1.

7.0   ANNEXURES – SOP FOR WATER PLANT:

Annexure 1: Purified Water Plant Log Sheet.

Sr.No. Mixed bed No. Date Time Conductivity in (Micro Siemens/cm) Purified water Temperature
RO water NMT 20 After Mixed bed NMT 5.1 Return Line NMT 5.1
 

 

 

UV hour meter pH Performed By Checked By Remarks
After Mixed bed  

After PW storage tank

Mixed bed outlet
Reading  (In Hours) Intensity (in %) Reading (in Days) Intensity (in %)

Annexure 2: Regeneration Log sheet.

Date Mixed Bed No Start time Back wash time (25 min) Prepare 100 lts. Caustic solution with 10 kg NaOH Prepare 100 lts. Acid solution with 25 lts 33% HCL Solution Prepared By Caustic solution injection time (25 to 30 min) Water wash time 45 min (slow rinse) & 25-30 min (fast rinse)

 

pH     (7 to 8) Acid solution injection time (25 to 30 min) Water wash time 45 -50min (slow rinse) & 25-30 min (fast rinse pH       (6 to 7) Air mixing time (25 min) Final Rinse (10 min) Stop time Checked By/Date Remarks

Annexure 3: U.V Lamp Replacement Status Label.

U.V LAMP REPLACEMENT STATUS LABEL

SANITIZER NO______________________________________________

U.V LAMP : – ___________________________________________________

REPLACEMENT AT : – _____________________________________ HRS

NEXT REPLACEMENT DUE AT:- ____________________________HRS

DONE BY:-_______________________________

CHECKED BY : – ______________________________________

Annexure 4: U.V Lamp Replacement Record.

U.V SANITIZER NO.
Sr.No. U.V Lamp Replaced on Hour/Day Meter Reading at the time of Replacement Next Replacement Due hours/Days Replaced By Checked By Remark

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pharmabeginers

Janki Singh is experienced in Pharmaceuticals, author and founder of Pharma Beginners, an ultimate pharmaceutical blogging platform. Email: [email protected]

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